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Restomod Air VAPIR 2 system Installation Instructions And Owner's Manual

Compact a/c
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VAPIR SYSTEM
INSTALLATION INSTRUCTIONS

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Summary of Contents for Restomod Air VAPIR 2 system

  • Page 1 VAPIR SYSTEM INSTALLATION INSTRUCTIONS...
  • Page 3 VAPIR SYSTEM Congratulations, you’ve got a Vapir... the highest performing, compact A/C in the after- market. You’ve joined an exclusive group of owners that demand only the best of the best for their classic rides. You’re going to love this thing, no matter what the weather is outside...
  • Page 4 VAPIR SYSTEM Check List, Pre-Installation: Before beginning the installation check the shipping box for the correct components. YOUR BOXED UNIT INCLUDES A LIST OF MAJOR COMPONENTS AND A LIST OF BAGGED PARTS. We have a 5 stage check process to make sure you have everything you’ll need. If your vehicle has been or is being modified, some procedures will need to be adjusted to fit your particular application.
  • Page 5 A Basic Overview of Automotive A/C..Evaporator with Blower Fan In order to remove the heat VAPIR SYSTEM from the air in the vehicle, the A/C evaporator allows the refrigerant to absorb the heat from the air passing over it. The blower fan moves cool air out into the car interior.
  • Page 6 Hardware box VAPIR SYSTEM Four Weldable Eight Zip Ties Studs SIX #10 - 16 x 3/4" Tek Screws Clear Plastic Drain Tube w/ 90 degree elbow and grommet Bracket mounting 1” Spacer (Front and Back) Four # 1/4 - 20 x 1" Bolts, Washer and Lock Nuts Two Remote Heat Dumps Unit heat Dumps Page 4...
  • Page 7 KNOW YOUR SYSTEM VAPIR SYSTEM Within the following pages we will outline the installation steps of your new Vapir system. Since this is a custom installation and varies based on your particular vehicle, many of our procedures can be viewed as “suggestions”...

  • Page 8: Electronics Box

    ELECTRONICS BOX VAPIR SYSTEM SIX #10 - 16 x 3/4" Tek Screws Electronic Water Control Valve Yellow Orange RESTOMOD ECU Page 6 www.restomodair.com 866.784.4278...
  • Page 9 Fitting box VAPIR SYSTEM TWO #6 FIO Straight Refrigerant Tape Six Worm Gear Clamps TWO #10 FIO Straight TWO #10 Straight Heater Fittings Page 7 www.restomodair.com 866.784.4278...

  • Page 10: Bench Calibration

    Bench calibration Connect YELLOW Harness into Defrost/Heat Servo Motor Connect ORANGE Harness into water valve Page 8 www.restomodair.com 866.784.4278...
  • Page 11 Bench calibration The next step is to utilize the main wiring harness and the two wire control harnesses we’ve included, wiring per this diagram. You have three ground wire connections on the main harness to make, one relay to secure, and one power supply to connect to your OEM fuse box.
  • Page 12 to complete your wiring of your VAPIR 2 REFER TO THE manual for the CONTROLS YOU PURCHASED www.restomodair.com 866.784.4278...
  • Page 13 VAPIR SYSTEM General Procedures and Vehicle Preparation Our Vapir system is designed to be flexible in it’s final mounting location, but generally the dash area behind the glove box area is the most common and practical. We’ve included several options for how you can mount the evaporator.
  • Page 14 Installation/general tips VAPIR SYSTEM Use whatever method you like to securely mount the • Mock up the installation, including evaporator (we show you two with the lines test fitted to make sure options on the next pages). you’ll have the room needed before you drill holes or weld the studs to your firewall.

  • Page 15: Bulkhead Installation

    Bulkhead installation ⁄ ” ⁄ ” ⁄ ” ⁄ ” Find a nice flat surface to install your bulk head and make sure that the area you selected is clear of any obstructions Standard sizes for the fitting are 13/16” for the heater and suction or components that can be damage.
  • Page 16 No bulkhead installation When drilling make sure to check for obstructions on either side of the firewall. We recommend using grommets if a bulkhead plate is not utilized. Route the hoses thru the fire wall into the engine bay. Page 14 www.restomodair.com 866.784.4278...
  • Page 17 Flat firewall installation ALI GN THI S LIN E WIT H FLO OR BO ALI GN THI S LIN E WIT H FLO OR BO Step 1 ALIGN THIS LINE WITH FLOOR BOARD ALIGN THIS LINE WITH FLOOR BOARD Tape template to inside firewall. Mark 4 locations (be sure to follow guide line for proper leveling) Page 15...
  • Page 18 Flat firewall installation Step 2 Weld 4 mounting studs in locations you marked. WELD MOUNTING STUDS TO INSIDE FIREWALL Page 16 www.restomodair.com 866.784.4278...
  • Page 19 Flat firewall installation Step 3 Roll evap under dash. Place onto mounting studs and secure with flange nuts. Page 17 www.restomodair.com 866.784.4278...
  • Page 20 BOLT-IN INSTALLATION ALI GN THI S LIN E WIT H FLO OR BO ALI GN THI S LIN E WIT H FLO OR BO ALIGN THIS LINE WITH FLOOR BOARD ALIGN THIS LINE WITH FLOOR BOARD Step 1 Tape template to inside firewall. Mark 4 locations (be sure to follow guide line for proper leveling) Page 18...
  • Page 21 BOLT-IN INSTALLATION 5/16∫ DRILL BIT Step 2 Drill Four 5/16” Holes thru firewall (be sure to check for obstructions first) Page 19 www.restomodair.com 866.784.4278...
  • Page 22 BOLT-IN INSTALLATION Engine Side Step 3 Roll evap under dash. Insert bolts from engine side and secure with flange nuts. Page 20 www.restomodair.com 866.784.4278...
  • Page 23 VAPIR SYSTEM Next, route all A/C and heater hoses from evaporator unit to your firewall. Make sure you have the correct orientation on the electronic water valve... IMPORTANT NOTICE... WATER VALVE MUST BE INSTALLED PER THESE INSTRUCTIONS: The lower connection on the tubes coming thru the block off assembly is going to be routed to the water outlet on the intake manifold.
  • Page 24 IN THE BOX VAPIR SYSTEM One Duct Hose, 2" I.D., 15’ Long (duct hose and lines will be in box, not bagged) FOUR #10 - 16 x 3/4" Tek Screws Choice of Defrost Ducts..Page 22 www.restomodair.com 866.784.4278...
  • Page 25 FLOOR DEFROST FLOOR We’ve included 15’ of flex hose for you to route to your choice(s) of main vents and defrost vents. The goal is measure, cut, and install hose sections that will be taunt, but not so tight that the individual lengths will be not have a bit of flexibility.
  • Page 26 Installing vents Installing Vents, a Quick Primer: Installing them will go very easily if you plan ahead and take your time. In some cases you may be able to use factory installed vents, if not, follow the following steps: A: While sitting in the vehicle, make a plan of where the vents will be located, situating them for maximum airflow and convenience.
  • Page 27 Engine compartment instructions IF YOU HAVE NOT DONE SO ALREADY, DISCONNECT THE BATTERY. During the next steps you’ll be installing the condenser, drier *, and routing the pressure switch* wire and the A/C lines. Since much of this is installed in the OEM location for the condenser, you’ll probably need to remove the center grill section, horn(s), and latch support assembly (see figure 37).
  • Page 28 CONDENSER PREP CONDENSER PREPARATION. Attach brackets using supplied #10-20 x 1/4” HEX HEAD screws to condenser mounting holes found on each side of condenser. The condenser must mounted to vehicle so that the larger fitting is on top (FAILURE TO DO SO WILL CAUSE AIR CONDITIONING SYSTEM TO FUNCTION INCORRECTLY). DRIER PREPARATION.
  • Page 29 CONDENSER PREP Place condenser in front of radiator and mount to radiator support with supplied #10-16 x 3/4” TEK screws or desired hardware. Condenser can be mounted with fitting connec- tions to either driver or passenger side. (MAKE CERTAIN #10-20 x 1/4” HEX-HEAD LARGE FITTING CONNECTION IS TO THE TOP.
  • Page 30 Passenger side compressor hose routing A: #6 Liquid Hose (5/16”) B: #8 Discharge Hose (13/32”) C: #10 Suction Hose (1/2”) Reminder... Use two wrenches to tighten o-ring fittings Page 28 www.restomodair.com 866.784.4278...
  • Page 31 Driver side compressor hose routing A: #6 Liquid Hose (5/16”) B: #8 Discharge Hose (13/32”) C: #10 Suction Hose (1/2”) Reminder... Use two wrenches to tighten o-ring fittings Page 29 www.restomodair.com 866.784.4278...
  • Page 32 VAPIR SYSTEM Re-install any components that had to be removed during the installation such as hood latch or grill. Page 30 www.restomodair.com 866.784.4278...
  • Page 33 VAPIR SYSTEM...
  • Page 34 Failure to follow this warning will most likely result in damaging the compressor and voiding the warranty. ADD OIL! All new compressors from Restomod Air contain a full system charge of oil. USE MORE THAN 24 oz. OF R134A REFRIGERANT! 1.5 lbs.
  • Page 35 90˚ DO NOT ADD OIL! All new compressors from Restomod Air contain a full system charge of oil. DO NOT CHARGE SYSTEM IN LIQUID FORM. Unlike later model vehicles, doing so will direct liquid refrigerant into the compressor piston chamber, causing damage to compressor reed valves and/or pistons, as well as potentially seizing the compressor.
  • Page 36 SYSTEMS! AVOID DAMAGING YOUR NEW A/C SYSTEM BY CLOSELY FOLLOWING THESE GUIDELINES! ADD OIL! All new compressors from Restomod Air Auto Air contain a full system charge of oil. USE MORE THAN 24 oz. OF 134a REFRIGERANT! 1.5 lbs. or 24 oz of R134A is what is required.
  • Page 37 RESULTS TEST DATE CONDITIONS (After system has been fully charged and tested for basic operation OUTSIDE TEMP • Determine the temperature outside of HIGH-SIDE PRESSURE the car READING (AT ENGINE IDLE) TARGET (150-250 PSI) • Close all doors and windows on vehicle LOW-SIDE PRESSURE READING (AT ENGINE IDLE) •...

  • Page 38: Troubleshooting Guide

    VAPIR SYSTEM TROUBLESHOOTING GUIDE TEST CONDITIONS USED TO DETERMINE SYSTEM OPERATION have a more pronounced affect on the unit’s cooling ability. Installing the valve improperly (such as having the flow reversed) will also allow water to flow through, thus inhibiting (THESE TEST CONDITIONS WILL SIMULATE THE AFFECT OF cooling.
  • Page 39 VAPIR SYSTEM Trouble Shooting Your Restomod Air A/C System PROBLEM: system is not cooling properly If the paper is held in place you are at least getting some air flow. If the high side decreases during test 2 & 3 then your condenser is not getting enough air which is ISSUE: cold at idle, warmer when raising engine RPM’s...
  • Page 41 VAPIR SYSTEM ALIGN THIS LINE WITH FLOOR BOARD ezhangr mounting template, Part 1...
  • Page 42 ALIGN THIS LINE WITH FLOOR BOARD ALIGN THIS LINE WITH FLOOR BOARD...
  • Page 43 VAPIR SYSTEM ALIGN THIS LINE WITH FLOOR BOARD ezhangr mounting template, Part 2...